User interface with real time pictograph representation of parameter settings

ABSTRACT

Provided is an electric arc generation system comprising a robot, an electric arc torch attached to the robot, a power supply configured to provide an electrical power output to the torch, and a user interface for adjusting a plurality of power supply parameters. The user interface comprises a display. The system includes a processor configured to receive respective settings of the plurality of power supply parameters, and configured to analyze the settings of the plurality of power supply parameters and control the display to display a pictograph warning associated with a current parameter setting, based on a result of analyzing the settings of the plurality of power supply parameters. Said pictograph warning graphically indicates an adjustment direction for the current parameter setting. The processor is configured to automatically adjust one or more of the settings of the plurality of power supply parameters based on a predetermined operating angle of the torch.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 15/665,590, filed on Aug. 1, 2017, the disclosure of which isincorporated herein by reference. Patent application Ser. No. 15/665,590claims the benefit of U.S. Provisional Patent Application Ser. No.62/403,315 filed on Oct. 3, 2016.

BACKGROUND OF THE INVENTION Field of the Invention

The present disclosure relates to controllers and user interfaces forarc generation power supplies, such as welding power supplies, plasmacutter power supplies, and the like. More particularly, the presentdisclosure relates to controllers and associated graphical userinterfaces that dynamically depict information in real time and in avisual or graphical manner, and methodologies for adjusting power supplyparameters using such controllers and user interfaces.

Description of Related Art

It is well known in the field of welding to adjust the parameters of awelding sequence to achieve a desired result. This may include settingthe welding power supply at a specific voltage or current, or at aparticular frequency. For some weldments, it may be desirable to achievedeep penetration of the weld joint whereas in another application, powersupply settings for deep penetration may damage or destroy the adjoinedmaterials. Accordingly, the operator may adjust one or more weldingparameters to match the material and joint configuration for aparticular application.

Gas Tungsten Arc Welding (GTAW) is one well known type of weldingprocess, known also as Tungsten Inert Gas (TIG) welding. Gas Metal ArcWelding (GMAW) and flux-cored arc welding (FCAW) are other well knownwelding processes. Stick welding (SMAW) and submerged arc welding (SAW)are yet other types of welding processes. Each welding process utilizesan electrode through which power is supplied from a welding power supplyto establish the welding arc. Examples of welding power supplies includephase controlled, pulse width modulated and inverter power supplies. Incertain welding processes, the electrode is consumed, as in the case ofGMAW, FCAW and Stick welding. By way of contrast, the electrode for theTIG welding process is non-consumable. In each type of welding, thewelding power supply parameters are set to control the weld cycle.

Parameters used to control the welding process include electrode feedrate, current and/or voltage. Some GMAW welding machines also have aninductance control that affects the response of the power source orsupply. Other welding parameters may include AC balance where the dutycycle of positive voltage is greater than that of the negative voltageby a particular percentage resulting in shallower arc penetration. Theconverse may also be true for deeper penetration. Other aspects of thewelding process, including arc width, or the kind of arc produced by thewelding power supply, are also affected by adjusting the weldingsequence or welding profile. Additional parameters used to control thewelding process include electrode stickout (i.e., the length that theelectrode protrudes from a contact tip), weave length for weave welding,weave shape or pattern, and weave frequency.

For proper control, the operating parameters should be set to optimalsettings for a particular application (e.g. gas mixture used, platethickness and joint type). Prior art welding machines have required theoperator to calculate setup parameters from tables or equations.Alternatively, the settings may be set based on welder experience, or bytrial and error.

If the welding operator provides erroneous data, or improperlycalculates the setup parameters, poor weld quality or inefficient use ofthe welding machine and consumables may result. Weld quality istherefore dependent upon proper setup of the welding parameters. Moreexperienced operators understand precisely what effects a particularadjustment in the welding profile will have on the weld joint. However,less experienced welders may experiment by adjusting the welding profilein various ways until the desired weld has been achieved. This canresult in reduced quality, lost productivity and increased materialcosts.

U.S. Pat. No. 7,781,700, issued on Aug. 24, 2010, incorporated herein byreference, discloses a welder user interface that helps an operator tounderstand how changes in the welding profile will affect the weldingprocess. A graphical display on the welding power supply allows theoperator to adjust welding parameters, such as aspects of the weldingwaveform, and visually observe how such changes will affect thewaveform. The graphical display also provides pictographs or icons thatshow how changes to welding parameters will affect the welding process.

It would be desirable to display intuitive, graphical indications ofimproper parameter settings to warn an operator of the improper settingsand their potential impact on the resulting weld. It would also bedesirable to provide the operator with parameter selections and/oradjustments in an intuitive, graphical manner. Welding and plasmacutting operations are often performed automatically by robots, and itwould be further desirable to incorporate graphical user controls forboth the robot and torch power supply in a single user interface.

BRIEF SUMMARY OF THE INVENTION

The following summary presents a simplified summary in order to providea basic understanding of some aspects of the devices, systems andmethods discussed herein. This summary is not an extensive overview ofthe devices, systems and methods discussed herein. It is not intended toidentify critical elements or to delineate the scope of such devices,systems and methods. Its sole purpose is to present some concepts in asimplified form as a prelude to the more detailed description that ispresented later.

In accordance with one aspect of the present invention, provided is anelectric arc generation system. The electric arc generation systemcomprises a robot, an electric arc torch attached to the robot, a powersupply configured to provide an electrical power output to the electricarc torch, and a user interface for adjusting a plurality of powersupply parameters. The user interface comprises a display. The systemfurther includes a processor configured to receive respective settingsof the plurality of power supply parameters. The processor is furtherconfigured to analyze the settings of the plurality of power supplyparameters and control the display to display a pictograph warningassociated with a current parameter setting, based on a result ofanalyzing the settings of the plurality of power supply parameters. Saidpictograph warning graphically indicates an adjustment direction for thecurrent parameter setting. The processor is configured to automaticallyadjust one or more of the settings of the plurality of power supplyparameters based on a predetermined operating angle of the electric arctorch.

In accordance with another aspect of the present invention, provided isan arc welding system comprises a robot arm, a robot controllerconfigured to control movement of the robot arm, a welding torchattached to the robot arm, a welding power supply configured to providean electrical power output to the welding torch, and a robot controlpendant operatively connected to the robot controller. The robot controlpendant comprises a user interface for adjusting a plurality of weldingparameters of the welding power supply, wherein the user interfacecomprises a display. At least one of the robot controller and the robotcontrol pendant includes a processor configured to receive respectivesettings of the plurality of welding parameters and automatically adjustone or more of the settings based on a predetermined welding angle ofthe welding torch.

In accordance with another aspect of the present invention, provided isan arc welding system, comprising a power supply configured to provide awelding output to a welding electrode, a user interface for adjusting aplurality of welding parameters, wherein the user interface comprises adisplay, and a processor operatively connected to the user interface toreceive respective settings of the plurality of welding parameters. Theprocessor is configured to analyze the settings of the plurality ofwelding parameters and control the display to display a pictographwarning associated with a current parameter setting based on a result ofanalyzing the settings of the plurality of welding parameters. Thepictograph warning graphically indicates an adjustment direction for thecurrent parameter setting. The processor is further configured todisplay a plurality of example weld bead pictographs along withgraphical indications of said adjustment direction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an example electric arc generation system;

FIG. 2 is a block diagram;

FIG. 3 is a screen shot of an example user interface;

FIG. 4 is a screen shot of an example user interface;

FIG. 5 is a screen shot of an example user interface;

FIG. 6 is a screen shot of an example user interface;

FIG. 7 is a screen shot of an example user interface;

FIG. 8 is a screen shot of an example user interface;

FIG. 9 is a screen shot of an example user interface;

FIG. 10 is a screen shot of an example user interface;

FIG. 11 is a screen shot of an example user interface;

FIG. 12 is a screen shot of an example user interface;

FIG. 13 is a screen shot of an example user interface;

FIG. 14 is a screen shot of an example user interface;

FIG. 15 is a screen shot of an example user interface;

FIG. 16 is a screen shot of an example user interface;

FIG. 17 is a screen shot of an example user interface; and

FIG. 18 is a flow diagram.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention relate to controllers and userinterfaces for arc generation power supplies, such as welding powersupplies, plasma cutters, cladding and hardfacing equipment, and thelike. More particularly, the present invention relates to roboticsystems that include such power supplies, and also controllers andassociated graphical user interfaces that dynamically depict informationin real time and in a visual or graphical manner, and methodologies foradjusting power supply parameters using such controllers and userinterfaces. The present invention will now be described with referenceto the drawings, wherein like reference numerals are used to refer tolike elements throughout. It is to be appreciated that the variousdrawings are not necessarily drawn to scale from one figure to anothernor inside a given figure, and in particular that the size of thecomponents are arbitrarily drawn for facilitating the understanding ofthe drawings. In the following description, for purposes of explanation,numerous specific details are set forth in order to provide a thoroughunderstanding of the present invention. It may be evident, however, thatthe present invention can be practiced without these specific details.Additionally, other embodiments of the invention are possible and theinvention is capable of being practiced and carried out in ways otherthan as described. The terminology and phraseology used in describingthe invention is employed for the purpose of promoting an understandingof the invention and should not be taken as limiting.

FIG. 1 shows an example robotic system 100. The system includes a movingmechanical assembly that supports a tool. The moving mechanical assemblycan be a robot 102, such as a six-axis articulating industrial robot armas shown, or other types of moving mechanical assemblies, such as anorbital pipe welder. An end of arm tool or end effector is attached tothe robot 102. Example end of arm tools include electric arc torches104, such as arc welding torches and plasma cutting torches.

For ease of explanation, aspects of the system will be discussed in thecontext of an electric arc welding system employing an arc weldingtorch. However, it is to be appreciated that such aspects are alsoapplicable to other types of systems and tools, such as plasma cuttersand the like.

The torch 104 can include an electrode 106, such as consumable wireelectrode, through which an arc 108 is generated between the torch and aworkpiece 110 to perform a welding operation on the workpiece. The robot102 controls the movements of the torch 104 during welding based oncontrol instructions from a computer-based robot controller 112. Withreference to FIG. 2, the robot controller 112 can include a processor111, memory 113, a user interface 114, and can further includeadditional components needed to control the movements of the robot 102.The memory 113 (e.g., non-transitory computer-readable medium) can storeprogrammed instructions that when executed by the processor 111 causesthe robot controller 112 to perform the functionality ascribed to itherein.

The robot controller 112 includes a handheld control pendant or teachpendant 116 operatively connected to the robot controller. The controlpendant 116 includes a user interface 118 having a display and varioususer inputs. The control pendant 116 can include its own processor 115,memory 117, etc. for storing programmed instructions that when executedby the processor causes the control pendant 116 to perform thefunctionality ascribed to it herein. Using the control pendant 116, anoperator can program or adjust various operations to be performed by therobot 102. The operator can also view on a display of the user interface118 information about the robot 102, and information about the operationthe robot performs on the workpiece 110 using the torch 106.

The system 100 further includes a power supply 120. The power supply 120provides an electrical power output to the torch 104 to generate the arc108. The power supply 120 converts input electrical power (e.g., utilitypower) into a suitable arc waveform (e.g., a welding waveform) forperforming an operation on the workpiece 110. The power supply 120 caninclude electronic circuitry (e.g., PWM inverters, choppers, etc.) forgenerating a desired arc waveform. The power supply 120 can furtherinclude a processor 119, memory 121, and a user interface 122 foradjusting various parameters of the operation performed on the workpiece110 (e.g., voltage, current, wire feed speed, AC balance, etc.) Like therobot controller 112 and control pendant 116, the memory 121 of thepower supply 120 can store programmed instructions that, when executedby the processor 119, causes the power supply to perform thefunctionality ascribed to it herein.

As shown in FIG. 2, the robot controller 112 and control pendant 116 areoperatively connected for bidirectional communications. Thecommunications can be wired or wireless. Various parameters of the robotcontroller 112 can be transmitted to the control pendant 116 and can beadjusted at the control pendant, for example through the user interface118 on the control pendant. The robot controller 112 can also beoperatively connected to the power supply 120 for bidirectionalcommunications therewith. The robot controller 112 and power supply 120can communicate operating information and parameter settings tocoordinate movements of the robot 102 with the state of the arc duringwelding of the workpiece 110. In certain embodiments, the robotcontroller 112 can set or adjust parameters in the power supply 120, andthe power supply can set or adjust parameters in the robot controller.The control pendant 116 can also receive and display power supplyparameters, either directly from the power supply or through the robotcontroller 112. Thus, the control pendant 112 can be operativelyconnected to the power supply 120 and can allow an operator to view andadjust power supply parameters directly from the control pendant.

The user interfaces 114, 118, 122 discussed above can include displaysfor graphically presenting parameters, such as robot parameters, weldingparameters, plasma cutting parameters, etc., to an operator in the formof pictographs, and visually showing the operator how changes to theparameters will affect a robot process, a welding process, a plasmaprocess, and the like. The representation of process changes asparameters are adjusted can occur in real time. That is, as a parameteris adjusted, the pictographic representation of the parameter, processor other result of the process will also change. Further, parameters canbe changed by selecting among a plurality of pictographicrepresentations of the parameters that respectively correspond todifferent values or settings of the parameter.

The displays of the various user interfaces 114, 118, 122 may becontrolled by electronic circuitry including display memory and displayprocessing circuitry. The display processing circuitry may include aseparate processor from one used to control the device in which thedisplay is located. The displays can be touchscreen displays, and thedisplays can be associated with various input devices, such as soft keysand rotary encoders, that form parts of the user interfaces 114, 118,122.

As noted above, the displays can show pictographs that depict a portionor parameter of a robot process, a welding process or the combination ofrobot movements and the welding process. For example, the display canshow a pictograph icon representing the tip of a welding torch, awelding electrode, and a workpiece. Parameter adjustments can bedepicted visually by changing the appearance of the pictograph in realtime. For example, if electrode stickout were to be adjusted, theadjustment can be displayed by changing (extending/retracting) thelength that the electrode appears to protrude from the welding torch.Also, the result of an adjustment to the stickout on the weld itself canbe shown pictorially or in an animated welding process. For example, theshape of a displayed weld bead (convex, concave, etc.) can change as thestickout is adjusted. Another example is changes to a weave patternperformed by the robot 102. As the operator changes a parameter such asweave frequency, a visual representation of either a “tighter or looser”weave can be displayed or simulated, and the resulting weld and theeffects on the weld (e.g., scalloping) can be shown. Moreover,pictographic warnings can be provided to the operator if certainparameter settings are determined to be incorrect. The pictographicwarnings could further graphically suggest how a parameter should bechanged (e.g., up, down, on, off, etc.) Such a pictograph-based displaymethodology can allow the operator to more easily understand the impactof parameter changes without having to actually weld with the changedsettings to appreciate their impact. As the operator changes the valuesor settings for different variables or parameters, rather than trying toimagine the parameter being changed and the impact of the change, thedisplays can provide a real time visual representation of the changebefore welding occurs. The graphical display of a parameter as apictograph, and the visual representation of the effect(s) on theresulting weld due to an adjustment of the parameter can provide ahighly intuitive control interface for an operator.

Various interface screens for controlling operations of the robot 112and power supply 120 will now be discussed. The interface screens can bedisplayed on any of the user interfaces 114, 118, 122 described above,under the control of any of the processors 111, 115, 119 describedabove. However, because the control pendant 116 is handheld andportable, it may be desirable to implement in the interface screens onthe control pendant and use the control pendant as a common userinterface for both the robot controller 112 and the power supply 120.

FIG. 3 is a screen shot of an example user interface for controlling awelding process including movements of the robot arm 102 (FIG. 1), andoperations of the power supply 120 and the generation of the arc 108.The screen in FIG. 3 is a main screen 300, from which various othercontrol screens can be selected. In particular, one or more screens forweld editing and tuning (Tuning 302), power supply status and variousmanual functions (Welder 304), seam tracking status and tuning(WolfTrack 306), welding mode selection (Setup 308), and other settings(Settings 310) can be accessed through icons the main screen 300.

FIGS. 4-6 provide screen shots 312, 314, 316 corresponding to weldingmode selection (Setup 308). Welding modes can be searched, selected andedited from the screens shown in FIGS. 4-6. A variety of differentavailable welding modes can be displayed and one selected for use and/orediting. Each welding mode can have a unique identifier (number, name,etc.) The selection of a particular welding mode can trigger the displayof properties corresponding to the selected mode, such as the weldingprocess to be performed (GMAW), gas type, electrode properties, wirefeed speed, voltage, current, and the like. The value of storedparameters for the selected welding mode can be displayed and changed ifdesired. In FIG. 4, a “Mode 21” has been highlighted. Selecting the“Info” icon 318 can launch screen 314 (FIG. 5), which provides detailedinformation about the selected welding mode. The selected welding modeor parameters of the selected welding mode can be communicated to thepower supply for use during a welding operation by the robot. Selectingthe “Search” icon 320 can launch a search screen 316 (FIG. 6) forsearching the various available welding modes according to specificparameters (e.g., welding process, wire type, gas type, etc.)

FIG. 7 provides a screen shot of a seam tracking status and tuning(WolfTrack 306) functions screen 318. Various parameters associated withweld seam tracking can be displayed and/or changed, such as: track mode,gain Y, gain Z, reference voltage, reference current, actual voltage,actual current, Y and Z corrections, etc. The current status 320 of theseam tracker can be displayed to the operator, such as whether or notthe seam tracker is active or in a fault condition, whether the trackingsensor(s) are Ok, whether an arc is detected, etc. The results ofchanging tracking parameters can be displayed as an image or animatedwelding simulation 322 to quickly convey the impact of the changes tothe operator.

FIG. 8 provides a screen shot of a power supply status and manualfunctions (Welder 304) screen 324. From this screen, power supplyparameters such as welding voltage, current, and wire feed speed can beviewed and adjusted. The current status 326 of the welding operation canalso be displayed, such as whether gas and water are activated and anyproblems associated therewith, whether the welding wire is stuck, etc.The screen 324 includes pictographs 328, 330 through which wire feedspeed can be adjusted up and down.

FIGS. 9-14 provide screen shots corresponding to weld editing and tuning(Tuning 302) screens. In FIGS. 9-10, welding and robot parameters suchas weld speed, weave length, weave width, dwell left, dwell right,welder mode, volts, and wire feed speed can be selected and adjusted ifdesired. Highlighting one of the welding or robot parameters in a firstwindow 332 can provide selections or an adjustment for the parameter ina second window 334. The effect of adjusting a parameter can bedisplayed graphically in a pictogram or an animation and/or in a textformat.

As noted above, the interface screens discussed herein can be displayedon the user interface 118 of the control pendant 116 (FIG. 2), andparameters for the robot 102 and power supply 120 can be set andadjusted using the control pendant. The processor 115 in the controlpendant 116 can receive the settings from the operator via the userinterface 118, and transmit the settings to the robot controller 112and/or power supply 120. The processor 115 in the control pendant 116can also receive current parameter settings from the robot controller112 and/or power supply 120 for display and adjustment by the operator.

The control pendant 116 can receive and/or store acceptable ranges ofparameter settings for comparison to current settings entered by theoperator. The processor 115 can analyze the current settings bycomparing them to the acceptable ranges received from the robotcontroller 112 or power supply 120. If an operator's current parametersetting is outside of the acceptable range, the processor 115 cancontrol the display to display a pictograph warning associated with thecurrent parameter setting indicating that the current setting is out ofrange. Moreover, the pictograph warning can graphically indicate arecommended adjustment for the current parameter setting, to move itwithin the acceptable range. For example, the pictograph warning couldshow a recommended adjustment direction for the parameter, or whetherthe parameter should be activated or deactivated. An example pictographwarning 336 is shown in FIG. 9 for the parameter WFS (wire feed speed).In window 334, it can be seen that the control pendant has received anacceptable, valid WFS range of 50 to 490 ipm (inches per minute) fromthe power supply for the current welding procedure. However, the WFSsetting is 661 ipm. Because the current WFS setting is outside of theacceptable range, the control pendant displays a pictograph warning 336in the form of a downward-pointing arrow having an exclamation point.The warning 336 can also incorporate color, such as red or yellow, toindicate that an adjustment is recommended. The pictograph imagesimultaneously provides a warning and indicates the recommendedadjustment direction (downward) for the parameter setting.

In FIG. 11 it can be seen that additional pictographic information canbe provided to the operator concerning the out-of-range parametersetting. Selecting the “Info” icon 338 will trigger the display of theadditional information for the highlighted parameter. The pictographicinformation can include an adjustment direction 340 for the parameter,and a cross-section of an improper weld bead 342. The adjustmentdirection 340 can inform the operator how to adjust the selectedparameter if the improper weld bead 342 occurs or is expected. Forexample, if a convex weld bead, burn through, undercut, excessivespatter or an erratic arc occurs or is anticipated, WFS should bereduced as indicated by the displayed adjustment direction 340.Conversely, if a concave bead or poor weld penetration occurs or isexpected, WFS should be increased. In certain embodiments, theout-of-range status of a parameter is used by the processor to displayonly additional pictographic information corresponding to a recommendedadjustment direction for the out-of-range parameter. In FIG. 9, forexample, because WFS is set too high and the recommended adjustmentdirection is downward, selecting the Info icon 338 can result in thedisplay of only additional information concerning the downwardadjustment of WFS, and the display of images of improper weld beads thatcould result if WFS is not adjusted downward. The improper weld beadscould also be displayed in an animated fashion if desired.

The weld editing and tuning screens can include a “Blocking” icon 342.Welding, seam tracking, and weaving can be activated and deactivatedfrom the weld editing and tuning screens by selecting the Blocking icon342 and then selecting an icon corresponding to the operation to beactivated/deactivated (FIG. 12).

FIGS. 13 and 14 show additional graphical information that can beconveyed to an operator. For example, the appearance of different weaveshapes 344 available for selection can be displayed, or different weavelengths 346 and/or frequencies. The resulting workpieces and weld beadcan also be displayed. For example, the resulting weld bead as weavefrequency is adjusted can be depicted. As shown in FIG. 14, the weaveshapes or patterns can be displayed in a perspective, three-dimensionalview, showing the height and width of the weave pattern along a travellength of the welding torch. An operator can select a desired weaveshape, frequency, length, etc., from among the displayed images, and therobot controller can control the motions of the robot arm to create aweld bead on the workpiece matching the selected image.

From the weld editing and tuning screens, welding templates can becreated or loaded for use during a welding operation. The templates canbe saved in one or more of the memories discussed above for access byone or more of the processors. The templates can contain both powersupply parameters and robot parameters for defining an entire orsubstantially entire welding operation. FIGS. 15-17 show exampletemplate screens. The weld editing and tuning screens (FIGS. 9-14) caninclude a “Templates” icon 348 for activating a template search screen350. From the template search screen 350, available stored templates canbe filtered based on criteria such as weld joint type, weld position(e.g., 1F-4F, 1G-4G, etc.), workpiece thickness, type of metal, or otherparameters. Certain filtering parameters can also be displayedpictographically 352, such as the weld joint type and weld position. Aspecific welding template can be selected from a list of templates 354meeting the filter criteria.

To display detailed information about a template, an “Info” icon 356 canbe selected. As shown in FIG. 16, the detailed information can includethe name of the template, its author, weld material, weld type andposition, material thickness, weld size, and other information (e.g.,weave pattern, weave length and frequency, power supply parameters,etc.) The templates can include CARW (computer assisted robotic welding)data 358, such as work angle range, travel angle range, level anglerange and roll angle range (torch angles). Selecting an “Info” icon 360associated with the CARW data can activate pictographic displays of theCARW data, as shown in FIG. 17. It can be seen in FIG. 17 that the CARWangle data are ranges of different welding or operating angles for thetorch. The ranges of welding angles can include a nominal value for thetorch angle in addition to maximum and minimum values.

In certain embodiments, the range of torch angles can be associated withpower supply parameters, such as voltage, current, WFS, etc. Theprocessor, such as the processor 115 in the control pendant 116 (FIGS. 1& 2), can automatically adjust one or more of the power supply parametersettings based on the actual torch angle during a welding operationdeviating from the range of torch angles in the template. If the torchangle as controlled by the robot during welding deviates from one of theranges in the template, the processor 115 can automatically adjustwelding parameter settings up or down during welding to accommodate thedeviation.

The actual torch angle during welding might have to deviate from theprogrammed ranges in the template to avoid obstructions on a workpiece.When welding within a ship, for example, an obstruction in the shipmight cause the torch angle to deviate from the ranges in the currenttemplate. When such a deviation occurs, the processor 115 in the controlpendant 116, or the processor in the robot controller 112, canautomatically adjust welding parameters to account for the deviation.For example, if the welding torch must be rotated into an overheadwelding position such that one or more of the torch angles deviates fromthe template, power supply parameters such as welding voltage or currentcould be reduced slightly, or the weave pattern changed or travel speedincreased, to accommodate the position of the torch. When the torchangle returns to the acceptable range in the template, the processor canautomatically return the welding parameter settings to their normalvalues.

In certain embodiments, workpiece data, such as a 3D CAD file, can bestored in a memory accessible by the processor. The workpiece data caninclude information about the location and size of potentialobstructions. The processor can analyze the workpiece data and plan arobot-controlled welding route, path or sequence from the workpiecedata. The processor can also plan predetermined torch angles as part ofthe welding route, path or sequence. If the predetermined torch anglesdeviate from the ranges in the template, the processor can store weldingparameter adjustments as part of the planned welding sequence.

FIG. 18 provides a flow diagram of an example process that can beperformed by one or more of the processors discussed above. A CAD fileconcerning a workpiece to be welded can be loaded into a memoryaccessible by the processor (step S10). From the data in the CAD file,the processor can determine a weld path (step S20) and identifyobstructions in the weld path (step S30). The processor can alsodetermine torch angles, such as work angle, travel angle and levelangle, along the weld path and in view of any identified obstructions(step S40). The processor can then compare the torch angles to thewelding template (step S50) and determine whether the torch angles arewithin the ranges stored in the welding template (step S60). If any ofthe torch angles deviate from the ranges in the welding template, theprocessor can store corresponding adjusted welding parameter settings(step S70).

Example parameters and other information that can be included in theinterface screens and/or templates discussed herein and displayedtextually and/or as pictographs or as part of welding animations,include the following:

Template Name, Author, Timestamp

Weld Size

Joint Type—Fillet, lap, bevel, v-groove, etc.

Joint Position—1F, 2F, 1G, 2G, etc.

Workpiece Material Type

Material Thickness (min and max)

CARW (computer assisted robotic welding) data:

-   -   Work Angle—torch to workpiece angle    -   Travel Angle—torch push/pull angle    -   Level Angle—describes how far joints can vary from ideal 1F, 2F,        etc., conditions and still achieve a desired result    -   Roll Angle—describes how far joints can vary from ideal 1F, 2F,        etc., conditions and still achieve a desired result

Welder and robot motion/timing controls:

-   -   Start data    -   Purge time    -   Preflow time    -   Scrape type    -   Start move delay    -   Ignition controls    -   Heat Phase Speed    -   Heat Phase Distance    -   Heat controls

Bead data:

-   -   Weld speed    -   Weave data, such as:        -   Weave length        -   Weave width        -   Dwell left        -   Dwell right    -   Weave Advanced data:        -   Weave shape        -   Weave type        -   Weave height        -   Dwell center        -   Weave direction        -   Weave tilt        -   Weave orientation        -   Weave bias            Additional (tracking) data:    -   Tracking type    -   Gain y    -   Gain z    -   Track bias    -   Max correction

End data:

-   -   Cool time    -   Fill time    -   Fill controls    -   Burnback time    -   Burnback controls    -   Rollback time    -   Postflow time

Each welder data can include:

-   -   Welder mode (e.g., to establish wire type, wire size, and gas        type)    -   Voltage    -   Wirefeed (e.g., speed)    -   Current (varies per mode)    -   Control_1 (varies per mode)    -   Control_2 (varies per mode)    -   Control_3 (varies per mode)    -   Control_4 (varies per mode)    -   Multipass parameters—data for subsequent passes in a multi-pass        weld, including tool location/orientation relative to root pass    -   Calculated Adaptive controls—for varying weld joints that        require adaptive deposition to fill properly    -   PowerWave through arc tracking control parameters    -   Interpass cleaning (grinding or needle scaling) requirements    -   Preheating requirements.

It should be evident that this disclosure is by way of example and thatvarious changes may be made by adding, modifying or eliminating detailswithout departing from the fair scope of the teaching contained in thisdisclosure. The invention is therefore not limited to particular detailsof this disclosure except to the extent that the following claims arenecessarily so limited.

What is claimed is:
 1. An arc welding system, comprising: a weldingtorch; a welding power supply configured to provide an electrical poweroutput to the welding torch; and a robot control pendant comprising auser interface for adjusting a plurality of welding parameters of thewelding power supply, wherein the user interface comprises a display,and the robot control pendant includes a processor configured to receiverespective settings of the plurality of welding parameters andautomatically adjust one or more of the settings based on a weldingangle of the welding torch, and wherein the processor is configured tocontrol the display to display simultaneously respective pictographsgraphically depicting a plurality of selectable weave shapes, andconfigured to output to a robot controller a selected one of theplurality of selectable weave shapes for controlling movements of thewelding torch.
 2. The arc welding system of claim 1, wherein theprocessor is further configured to analyze the settings of the pluralityof welding parameters and control the display to display a pictographwarning associated with a current parameter setting, based on a resultof analyzing the settings of the plurality of welding parameters,wherein said pictograph warning graphically indicates an adjustmentdirection for the current parameter setting.
 3. The arc welding systemof claim 2, wherein said processor is further configured to display aplurality of weld bead pictographs along with graphical indications ofthe adjustment direction.
 4. The arc welding system of claim 2, whereinthe processor is further configured to compare the settings of theplurality of welding parameters to one or more ranges of settingssupplied by the welding power supply.
 5. The arc welding system of claim1, further comprising a memory accessible by the processor and storing awelding template that includes the settings of the plurality of weldingparameters and a range of welding angles, wherein the processor isconfigured to automatically adjust said one or more of the settings ofthe plurality of welding parameters when the welding angle is outside ofthe range of welding angles.
 6. The arc welding system of claim 5,wherein the welding angle is predetermined by the processor and includeseach of a work angle, a travel angle, and a level angle, and the rangeof welding angles includes each of a work angle range, a travel anglerange, and a level angle range.
 7. The welding system of claim 1,further comprising a robot controller, wherein the robot control pendantis operatively connected to the robot controller.
 8. An arc weldingsystem, comprising: a power supply configured to provide a weldingoutput to a welding electrode; a welding torch that includes the weldingelectrode; a user interface for adjusting a plurality of weldingparameters, wherein the user interface comprises a display; and aprocessor operatively connected to the user interface to receiverespective settings of the plurality of welding parameters, wherein theprocessor is configured to analyze the settings of the plurality ofwelding parameters and control the display to display a pictographwarning associated with a current parameter setting based on a result ofanalyzing the settings of the plurality of welding parameters, whereinsaid pictograph warning graphically indicates an adjustment directionfor the current parameter setting, and wherein said processor is furtherconfigured to display a plurality of example weld bead pictographs alongwith graphical indications of said adjustment direction, wherein theprocessor is configured to automatically adjust one or more of thesettings of the plurality of welding parameters based on a predeterminedwelding angle of the welding torch, and the processor is configured tocontrol the display to display simultaneously respective pictographsgraphically depicting a plurality of selectable weave shapes, and outputa selected one of the plurality of selectable weave shapes to controlmovements of the welding torch.
 9. The arc welding system of claim 8,wherein the processor is further configured to compare the settings ofthe plurality of welding parameters to one or more ranges of settingssupplied by the power supply.
 10. The arc welding system of claim 8,further comprising a memory accessible by the processor and storing awelding template that includes the settings of the plurality of weldingparameters and a range of welding torch angles, wherein the processor isconfigured to automatically adjust said one or more of the settings ofthe plurality of welding parameters when the predetermined welding angleis outside of the range of welding torch angles.
 11. The arc weldingsystem of claim 10, wherein the predetermined welding angle includeseach of a work angle, a travel angle, and a level angle, and the rangeof welding torch angles includes each of a work angle range, a travelangle range, and a level angle range.
 12. The arc welding system ofclaim 8, further comprising a robot control pendant that includes theuser interface and the processor.
 13. An arc welding system, comprising:a welding torch; a welding power supply configured to provide a weldingoutput to the welding torch; and a robot control pendant comprising auser interface for adjusting a plurality of welding parameters of thewelding power supply, wherein the user interface comprises a display,and the robot control pendant includes a processor configured to controlthe display to display simultaneously respective pictographs graphicallydepicting a plurality of selectable weave shapes, and output a selectedone of the plurality of selectable weave shapes to control movements ofthe welding torch; and wherein the processor is further configured toreceive respective settings of the plurality of welding parameters andanalyze the settings of the plurality of welding parameters and controlthe display to display a pictograph warning associated with a currentparameter setting, based on a result of analyzing the settings ofplurality of welding parameters, wherein said pictograph warninggraphically indicates an adjustment direction for the current parametersetting.
 14. The arc welding system of claim 13, wherein the processoris further configured to display a plurality of example weld beadpictographs along with graphical indications of said adjustmentdirection.
 15. The arc welding system of claim 13, wherein the processoris further configured to compare the settings of the plurality ofwelding parameters to one or more ranges of settings supplied by thewelding power supply.
 16. The arc welding system of claim 13, furthercomprising a memory accessible by the processor and storing a weldingtemplate that includes the settings of the plurality of weldingparameters and a range of welding angles, wherein the processor isconfigured to automatically adjust said one or more of the settings ofthe plurality of welding parameters when a welding angle of the weldingtorch is outside of the range of welding angles.
 17. An arc weldingsystem, comprising: a welding torch; a welding power supply configuredto provide an electrical power output to the welding torch; and a robotcontrol pendant comprising a user interface for adjusting a plurality ofwelding parameters of the welding power supply, wherein the userinterface comprises a display, and wherein the robot control pendantincludes a processor configured to control the display to displaysimultaneously respective pictographs graphically depicting inperspective three-dimensional views of a plurality of selectable weaveshapes, and output to a robot controller a selected one of the pluralityof selectable weave shapes.
 18. The arc welding system of claim 17,wherein the processor is further configured to receive respectivesettings of the plurality of welding parameters and analyze the settingsof the plurality of welding parameters and control the display todisplay a pictograph warning associated with a current parametersetting, based on a result of analyzing the settings of the plurality ofwelding parameters, wherein said pictograph warning graphicallyindicates an adjustment direction for the current parameter setting. 19.The arc welding system of claim 18, wherein the processor is furtherconfigured to display a plurality of example weld bead pictographs alongwith graphical indications of said adjustment direction.
 20. The arcwelding system of claim 18, wherein the processor is further configuredto automatically adjust one or more of the settings based on a weldingangle of the welding torch.